Om C400TM

C400TM operation and maintenance manual _eng -1-
ZMM-SLIVEN
Machine tools
C400TM
UNIVERSAL LATHE
OPERATION AND MAINTENANCE
MANUAL
ZMM-SLIVEN AD – SLIVEN
INTRODUCTION......................................................................................................... 4
PRODUCT APPLICATION …………...........................................................................5
SAFETY NORMS…………….......................................................................................6
1. PASSPORT DOCUMENTS………............................................................….…7
2. PACKING LIST………………………………………..........................................14
2.1 Standard units………..…………..…………………………………………….......14
2.2 Special execution…..……….………………………………………………..........14
2.3 Additional accessories…..…............................................................................14
2.4 Indispensable spare parts……………..............................................................15
3. TECHNICAL SPECIFICATION ………..…………………………………………16
3.1 Working zone…….………………………………………………………………….19
3.2 Connecting dimensions of spindle………………………………………………..21
4. LABOUR SAFETY………................................................................................22
4.1 Safety measures……………………………………………………………………22
4.2 Protection during operation…………………………………………………… ….22
4.3 Requirements for the machine……………………………….…………… ……..22
4.4 Safety devices built in in the machine……….………………………… ………..23
4.5 Requirements when repairing the machine………………….…………… …….23
5. MACHINE INSTALLATION……………...........................................................24
5.1 Packing and transportation………………………………………………………..24
5.2 Storage………………………………………………………………………………24
5.3 Unpacking…………………………………………….... ………………………….24
5.4 Lifting and handling……………………………………………………..…….……25
5.5 Removal of conservation stuff………………………………...…………………..26
5.6 Positioning, foundation and levelling……………………………………………..27
5.7 Connection to the electric mains………………………………………………….29
5.8 Commissioning into operation…………………………..………………………...29
5.9 Emergency stop………………………………………………………………….…30
6. TECHNICAL DESCRIPTION ..........................................................................31
6.1 Machine main units and controls …………………….......................................31
6.2 Kinematic diagram………................................................................................34
6.3 Main unit general information………................................................................35
6.3.1 Bed...................................................................................................................35
6.3.2 Gearbox...........................................................................................................35
6.3.3 Quadrant..........................................................................................................35
6.3.4 Feed box………………....................................................................................36
6.3.5 Apron……..…..................................................................................................36
6.3.6 Lower carriage.................................................................................................37
6.3.7 Upper carriage.................................................................................................37
6.3.8 Tailstock..........................................................................................................38
7. ADDITIONAL ACCESSORIES…………………..............................................39
7.1 Clamping and driving devices……………….…………………………………....39
7.2 Rests………..……………………………………………………………………….39
7.3 Taper turning attachment………………………………………………………….39
7.4 Thread indicator……………………...……………………………………………..39
8. SERVICING ………………………...………………………………………………40
8.1 General instructions…………………………………………….………………….40
8.2 Daily servicing………………………………………………………………………40
8.3. Weekly servicing………………...………………………………………………….40
8.4 Monthly servicing……………......................................................................... 40
8.5 Annual servicing……………...........................................................................40
9. LUBRICATION................................................................................................41
9.1. Lubricants……….............................................................................................42
9.2. Lubrication instructions……............................................................................43
10. OPERATING THE MACHINE..........................................................................44
10.1 Speed selection………………...………............................................................45
10.2 Feed drive…………………..............................................................................45
11. SETTING UP FOR DIFFERENT THREADS AND FEEDS………..................48
11.1 Multistart thread cutting ….………………........................................................48
11.2 Cutting of Taper Pipe Threads (Briggs threads)…………...............................48
11.3 Turning………..................................................................................................49
12. CLAMPING AND DRIVING DEVICES………….............................................51
13. ADJUSTING THE ADDITIONAL ACCESSORIES..........................................54
13.1 Thread indicator for pitch re-entering………....................................................54
13.2 Taper turning attachment.................................................................................56
13.3 Emergency stop limiter....................................................................................57
13.4 Rests................................................................................................................58
14. COOLING SYSTEM…………..........................................………………………61
15. ADJUSTING OF MECHANISMS……..............................................………....62
15.1 Gear box clutch adjustment………………………………………………………62
15.2 Gear box strap brake adjustment…………………………………………………62
15.3 Adjustment of bearing clearance of spindle .………........................................62
15.4 Belt tensioning.….............................................................................................62
15.5 Lead screw axial clearance adjustment…………..……...................................64
15.6 Setting of shear pin on lead screw…………….................................................65
15.7 Adjusting of cross slide safety clutch …………………….................................65
15.8 Adjusting the clearance of the nuts and the screw of the cross slide .............66
15.9 Adjustment of the clearance between the body guideways and the apron
plate……………………………………………………………...…………………..66
15.10 Adjusting the clearance between cross slide and carriage plate……..............67
15.11 Adjusting of tailstock for cylindrical and taper surface turning.........................68
15.12 Adjusting of gear box for cylindrical surface turning…....................................70
15.13 Adjustment the Position of the Handle for Safety Handwheel turn Off when
cross drive is turned On …………………………………………………………70
15.14 Apron protection device……………………………………………………..……72
16. PROTOCOL OF MACHINE GEOMETRICAL ACCURACY ......................….73
16.1 Preliminary examinations ………. .................................................................73
16.2 Geometrical tests............................................................................................74
16.3 Practical tests.................................................................................................76
17. ELECTRICAL INSTALLATION…………........................................................77
17.1 General ….......................................................................................................77
17.2 Protections......................................................................................................78
17.3 Electric controls …..........................................................................................78
17.4 Maintenance ………........................................................................................79
INTRODUCTION
This Manual contains detailed information about the safety norms, technical
servicing, and operating, the description and function of the C400TM universal lathe.
Strict compliance with the requirements shall ensure long service life and
accurate and trouble-free operation of your machine.
THEREFORE IT IS IMPERATIVE TO MAKE YOURSELF FAMILIAR WITH

THE OPERATION AND MAINTENANCE MANUAL AND THE OTHER
ACCOMPANYING DOCUMENTATION BEFORE COMMENCING INSTALLATION
AND OPERATION OF THE MACHINE
The machine design is being improved continuously by our company experts,

and your machine may prove to have parameters better than those, specified in the
manual.
Should you face any problem, which you may not resolve by your own efforts,
please contact ZMM-Sliven AD.
TELEPHONE: (+359 44) 662 890

FAX: (+359 44) 665 263
Е-МАIL: zmmsliven@zmmsliven.com
PRODUCT APPLICATION
The following operations can be performed with the C400TM universal lathe:
turning of cylindrical, taper and shaped surfaces; boring of cylindrical and taper holes
with longitudinal and transverse feed; cutting of all standard thread types – outer and
inner – metric, inch, module and diametral pitch threads.
The machine is intended for use in unit- and small- batch production.
Workpiece material may be steel, cast iron, non-ferrous metals and alloys. To
machine long shafts the machine is equipped with a follower rest and a steady rest.
The machine is equipped with a wide range of standard units and special
accessories, aimed at expanding its field of application. This machine operates in
closed rooms with 300 lx illumination at an ambient temperature of +50...+400 and air
humidity from 30% ...90%.
SAFETY STANDARDS
The safety standards, described in principle below should be complied with

strictly at the time and during all phases of operation of the machine.
Non-compliance with such safety standards may render the safety systems and
standards, which are envisaged at the time of machine designing and construction
inefficient.
Maker’s company shall bear no responsibility for damage of the machine or
faults, caused by the machine user, ensuing as a result of non-observance of the
safety standards, specified below:
- THE MACHINE SHOULD BE INSTALLED AND COMMISSONED INTO
OPERATION BY COMPETENT AND ADEQUATELY INSTRUCTED PERSONNEL.
- DURING TRANSPORTATION OR WHEN LIFTING THE MACHINE MAKE
SURE THAT YOU ARE ACTING WITH THE NECESSARY PRECAUTION AND
FOLLOWING THE INSTRUCTIONS, SET OUT IN THE RESPECTIVE SECTION.
- THE MACHINE USER SHOULD MAKE SURE THAT ALL
INSTRUCTIONS, CONTAINED IN THIS MANUAL ARE STRICTLY OBSERVED.
- ANY ACTION ON THE MACHINE THAT MAY BE IN CONTRADICTION
WITH THE SAFETY REQUIREMENTS, REPRESENTS A RISK FOR THE
OPERATOR.
- MAINTENANACE AND REPAIR SHOULD BE CARRIED OUT BY
PERSONNEL, WHO ARE INSTRUCTED AND WHO OBSERVE THE
INSTRUCTIONS SET OUT IN THIS MANUAL.
- PRIOR TO COMMENCING ANY MAINTENANCE AND/OR/ ADJUSTMENT,
MAKE SURE TO DISCONNECT THE POWER SUPPLY.
- EVENTUAL MODIFICATIONS OF THE MACHINE MAY BE CARRIED OUT
ONLY AND EXCLUSIVELY BY PERSONNEL AUTHORIZED BY MAKER’S
COMPANY.
- CONTACT OF THE MACHINE WITH WATER IS NOT ALLOWED.
1. PASSPORT DOCUMENTATION
Passport data
Type.........................................................................................
Distance between centers.......................................................
Supply voltage 3х.......V±5%;............Нz±5%
Installed capacity...............................................................кVА
Main electric motor..................кW..........V........ Нz............RPM.
Normal execution Special execution

Metric Inch
Normal climatic
For dry tropical climate
For wet tropical climate
Factory No.........................................
Certificate of Quality
ZMM – Sliven AD
Model..........................................................
Factory No...............................................
This Certificate of Quality has been issued based on the product test
protocol.
The products specified in the Certificate of Quality meets:
Ф10.03.00-2, as well as the norms valid under DIN 8606; the technical
requirements for delivery and are released for shipment.
Notes concerning storage, transportation, accompanying documents
and others.
....................................................................................................................
....................................................................................................................
....................................................................................................................
........................
Date.............20....... Quality
inspector:.....................................
(Name, Family name,
Signature)
Certificate for completeness

ZMM – Sliven AD
MODEL: Universal lathe ................................................

FACTORY No...................................................................
The lathe is completed in accordance with the contract for scope of

supply and the technical documentation.
Date:.............20...... Head of Commercial

Dept.:........................
Head of Production
Shop:..........................
Head of Quality
Dept:.................................
C400TM operation and maintenance manual _eng - 10 -
Packing Certificate
ZMM – Sliven AD
MODEL: Universal lathe.......…............................................

FACTORY No:.......................................................................
YEAR OF PRODUCTION:......................................................
Has been packed at the ZMM – Sliven AD company in accordance

with the requirements of the documentation.
Date of packing:......................................................
Head of Production
Date.............20....... Dept:…...............
Head of Quality
Dept:........................
Conservation Certificate
ZMM – Sliven AD
MODEL: Universal lathe...........…............................................

FACTORY No............................................................................
Has been conserved at ZMM – Sliven AD in accordance with the

requirements of the documentation.
Date of conservation:......................................................
Head of Production
Date.............20...... Dept:……............... Head of
Quality Dept:...........................
Warranty Certificate
ZMM – Sliven AD
MODEL: Universal lathe………….............................................

FACTORY No:.........................................................................
PRODUCED:…………..…………………...........................................
SHIPPED:………......................................................................
This Warranty Certificate is valid for one year from the date of
commissioning of the machine at client’s premises, however for not more
than 18 months from the date of shipment to the end client.
Any deviation from the technical specification found within the above
time period shall be eliminated by maker’s factory free of charge.
Within the warranty period maker’s company shall not be
responsible in the following cases:
- non-observance of the technical servicing requirements or the
contract clauses;
- improper transportation;
- emergency situations, hammering and mechanical damage due to
improper handling and installation;
- not trained and inadequately qualified specialists operating the
machine;
- record of claims presented is untruthfully completed.
Head of Quality
Date.............20...... Dept:............................
Deputy
Director:....................................
Record of Claims
Name and family name

Item
Date Content of the claim of persons who have Note
No
eliminated the claim
2. PACKING LIST
Type........................................................................
Distance between centers.................................mm
FACTORY No......................20.........
The units and the spare parts the machine is completed with are marked with
“x” in the respective square.
Item Name Pcs Note

2.1 STANDARD UNITS
2.1.1 Main motor 1 In machine
2.1.2 V-belt В17; Li=2020 4 In machine
2.1.3 Change gear z=57 at 19 rev/1” 1 In box
Set of bolts and plates for leveling
2.1.4 at distance between centers 750, 1000, 1500 8 In box
2.1.5 Electrical equipment – complete set 1 In machine
2.1.6 Cooling system with pump – complete set 1 In machine
2.1.7 Lighting body – complete set 1 In machine
2.1.8 Rapid traverse 1 In machine
2.1.9 Gap bridge 1 In machine
2.1.10 Adapter sleeve - Morse 6/ Morse 4 1 In box
2.1.11 Dead center – Morse 4 1 In box
2.1.12 Universal chuck flange Ø200 with bolts, a set 1 In slide
2.1.13 Rear splash guard 1 In machine
2.1.14 Guard for chuck 1 In machine
2.1.15 Guard for tool holder 1 In machine
2.1.16 Four position tool post 1 In machine
2.1.17 Operation and maintenance manual 1 In box
2.1.18 Box with tool kit 1 In slide
2.1.19 Packing – in slide 1
2.2 SPECIAL EXECUTION

2.2.1 Inch
2.2.2 Inch-metric ( with inch and metric graduated vernier)
2.2.3 Metric-inch ( with inch-metric graduated vernier)
2.2.4 Camlock type
2.2.5 Execution of power supply, other than 220/380V and
50НZ frequency
Voltage..........................,Frequency.........................
2.3 ADDITIONAL ACCESSORIES

/delivered upon special order, against additional
payment/
2.3.1 Selfcentering, three-jaw, universal chuck, ∅200 1 In slide
2.3.2 Non-selfcentering four-jaw chuck ∅320 1 In slide
2.3.3 Facing head ∅320 1 In slide
2.3.4 Drive plate 1 In slide
2.3.5 Emergency stop pedal – complete set 1 In machine
2.3.6 Thread indicator for pitch re-entering 1 In machine
Item Name Pcs Note

2.3.7 Turning dogs: 20;30;40;50;60 complete set 1 In box
2.3.8 Morse adapter for chuck ∅20 1 In box
2.3.9 Chuck ∅20 1 In box
2.3.10 Rotating center – Morse 4 1 In box
2.3.11 Follower rest - ∅ 10 - ∅ 80 1 In machine
2.3.12 Steady rest - ∅ 10 - ∅ 100 1 In machine
2.3.13 One-position longitudinal stop limiter 1 In machine
2.3.14 Roller quill for rest 3 In box
2.3.15 Taper attachment 1 In machine
2.3.16 Electrodynamic brake – complete set 1 In machine
2.3.17 Adapter sleeve for tailstock – Morse 4/ Morse 3 1 In box
2.3.18 Wrenches – complete set 1 In box
2.3.19 Packing 1
2.4 INDISPENSABLE SPARE PARTS

2.4.1 Shear pin for lead screw 2 In box
2.4.2 Multiple disk clutch shoe 1 In box
3 . TECHNICAL SPECIFICATION
MEASUR
PARAMETER VALUE
ING UNIT
MAIN DIMENSIONS
mm 200
Center height above guideways
inch 7¾
Guideways width mm 320
1
inch 12 /2
Maximum turning diameter:
mm 400
Over bed
inch 15 ¾
mm 235
Over carriage 1
inch 9 /4
mm 550
With removed gap bridge 5
inch 21 /8
mm 10 - 80
In follower rest 3 1
inch /8 – 3 /8
mm 10 - 100
In steady rest – І 3 15
inch /8 – 3 /16
Machined length at removed gap bridge before non-selfcentering four-jaw mm 176
15
chuck face inch 6 /16
kg 100
Maximum weight of workpiece in chuck
slug 7
kg 250
Maximum weight of workpiece in chuck with back center
slug 18
kg 500
Maximum weight of workpiece in chuck with back center and rest
slug 35
SPINDLE
Spindle nose according to ISO702-II/USAS B5.9D1 ISO702-III/DIN 55027 Size 6
Inner taper Мorse 6
mm 52
Diameter of the cylindrical hole of the spindle 3
inch 2 /64
mm 80
Diameter of front bearing 5
inch 3 /32
RAPID STROKE
Number of speed ranges Number 12
-1
Speed range min 50 - 2240
DRIVES
Power of main motor kW 4
-1
Speed of rotation min 1450
Power of motor for rapid stroke kW 0.25
-1
Power of motor for coolant pump kW 0.09
-1
POWER SPECIFICATION
-1
Minimum spindle rpm at which full power is transmitted to spindle min 70
Maximum torque at spindle daN.m 40
Maximum pulling force of feed drive daN 200
LEAD SCREW
mm 35
Diameter 3
inch 1 /8
MEASUR
PARAMETER VALUE
ING UNIT
Pitch:
mm
Metric execution 10
inch 2
Inch execution /5
FEEDS
Number of feeds Number 80
Range of longitudinal feeds mm/rev 0.015 – 0,6
Range of crosswise feeds mm/rev 0.0075 – 0,3
THREADS
Number of threads Number 40
Thread range:
metric mm 0.25 -7,5
inch T/inch 120 - 4
module mm 0.0625 – 1,875
diametral pitch T/π” 480 - 16
CARRIAGE
mm 235
Cross slide travel 3
inch 9 /8
mm 110
Maximum travel of compound slide 3
inch 4 /8
0
Maximum angle of rotation degree ±90
FOUR POSITION TOOL POST
mm 23
Distance between tool post surface for supporting tools and the center line 7
inch /8
mm 20 х 20
Tool cross section 3 3
inch /4 х /4
0 0
Angle of rotation degree 360 /4х90 /
TAILSTOCK
mm 50
Quill diameter 15
inch 1 /16
Inner taper of quill Мorse 4
mm 100
Quill stroke 15
inch 3 /16
mm ±10
Crosswise stroke of tailstock 25
inch ± /64
NON-SELFCENTERING FOUR-JAW CHUCK
mm 320
Diameter 5
inch 12 /8
-1
Maximum speed min 900
FACING HEAD
mm 320
Diameter 5
inch 12 /8
-1
Maximum speed min 900
TAPER ATTACHMENT
mm 250
Maximum machined length
inch 9¾
0
Maximum inclination of taper forming degree ±10
RAPID STROKE OF CARRIAGE
mm/min 2800
Longitudinal 1
inch/min 110 /4
mm/min 1400
Crosswise 1
inch/min 55 /8
OVERALL DIMENSIONS
Length:
mm 2100
Distance between centers 750
inch 83
Distance between centers 1000 mm 2350
MEASUR
PARAMETER VALUE
ING UNIT
inch 93
mm 2850
inch 112
mm 980
Width
inch 39
mm 1330
Height
inch 53
Weight:
kg 1530
slug 104
kg 1590
slug 108
kg 1700
slug 116
3.1. WORKING ZONE
Designation Dimension, mm
A B C D E G K L H F
С400ТM 235 400 550 235 40 22 19 41 200 23
Fig.3.1.1
Designation Dimension, mm
M N P Q S
С400ТM 290 257 33 73 157
Fig.3.1.2
3.2. CONNECTING DIMENSIONS OF SPINDLE

DIN 55027 / ISO 702 ІІІ
Type A B C D E F Bolt
6 Ø170 Ø106,385 14 25 Ø23 Ø 133,4±0,1 4хМ12
Fig.3.2.1
USAS B5.9
Type A B C D E F
6 Ø181 Ø106,375 14 45 Ø23 Ø133,4±0,1
Fig.3.2.2
4. LABOUR SAFETY
4.1. SAFETY MEASURES
The machine is designed and produced in a way ensuring safety for the
operating personnel, only provided such personnel strictly abides by these
instructions
All materials used to produce different units and parts are tested in advance
and their specifications meet the necessary requirements.
4.2. SAFETY PRECAUTIONS DURING OPERATION
The machine is designed in accordance with the basic requirements of the

European safety standards and equipped with all necessary safety means.
The machine should be operated by persons having the necessary qualification,
which permits them to use such type of machines.
Operators having insufficient knowledge of the machine should be given the
required instructions and practical work, before they start operating the machine by
themselves.
The control and the starting up of the machine into operation should be carried
out by persons of qualification sufficient to permit them understand the specifications
and the sequence of the different operations.
Regardless of all precautions which may be taken in order to avoid danger of a
more frequent nature, the machine has potential hazards too, which can be avoided
by the operator, provided he is controlling carefully all phases of the operation of the
machine. Such hazards may come from the tool zone in case tool parts are not fixed
well and could slip away and fall down, or from insecurely clamped workpiece.
4.3. REQUIREMENTS FOR THE MACHINE.
The following is not allowed:

To operate the machine with open covers of quill, electric cabinet or with chuck
guard lifted up.
To operate the machine in the event of faulty interlocking of quadrant cover and
chuck guard.
To start up a machine or an electric cabinet, which have not been earthed in the
specified places.
To operate a machine, the electrical resistance of which exceeds 0.1Ω, when
measured between the earthing bolts and any machine part.
To operate a machine when the supply voltage has changed by more than
±10% of its rated value.
Repair works on the electrical installation when the machine supply is
connected to the mains.
To operate a faulty machine while the reasons, causing the defect are not
eliminated.
To operate a machine with increased clearance of slides of more than the
admissible 0.03 mm.
To operate with insecurely fastened tool, carbide tips of bad soldering quality,
insecurely fastened carbide change tips.
Operation at inadequate cutting mode and cutting tool.
Operation between centers with insecurely clamped tailstock.
To operate the machine under inadequate working place organization, working

zone contaminated with oil or coolant; piling up of workpieces, tools and other items,
which hamper the normal handling and running of the machine.
Chip removal from working zone when the machine is still working.
Operation under lighting not meeting the norms, excess noise and vibrations.
4.4. SAFETY DEVICES BUILT IN THE MACHINE

Safety lever for connecting the clutches for forward and return stroke.
Safety handwheel for apron.
Safety handle for cross slide.
Electric interlocking for electric cabinet door
Electric interlocking for cover of quadrant.
Rear shield of machine.
Front shield of machine.
Chuck guard
Lead screw and feed shaft protection.
Zero protection – earthing of machine and electric cabinet.
Maximum current protection.
Maximum heat protection.
Operating circuit 24V 50/60 Нz taken from division transformer.
4.5. REQUIREMENTS WHEN REPAIRING THE MACHINE
- The personnel, responsible for the repair, should have a detailed knowledge of
the machine and its control;
- Should the fault be of a more specific technical nature, please ask for
assistance from the service department of maker’s factory;
- When assembling the machine, make sure that all components are well
tightened;
- When dismantling and assembling the machine, make sure not to subject the
machine parts to hammering or heat influence, to avoid damage;
- Dismantling or isolating of interlocking switches is strictly forbidden;
- Safety devices, included in equipment, may not be changed, damaged or
removed.
5. INSTALLATION OF MACHINE
5.1. PACKING AND TRANSPORTATION.
The machine is transported in a special crate or set only on a wooden slide. It is

fixed to the slide by means of bolts. A portion of the units is mounted in the lathe,
while the smaller ones are packed in a separate box, fastened on the slide. Places
where ropes or chains are passing when the packed machine is lifted and handled,
are marked on the packing (on the large walls of the crate).
No pushing and hammering is allowed when lifting and handling the machine
with the packing. Machine packing should be inspected immediately upon arrival of
the machine.
Attention!
Ropes to conform to the weight of the machine!
Machine to be handled by crane of a loading capacity equal or
higher than the weight of the machine, which is specified in this
manual. Fastening of ropes and crane operation to be carried out
by qualified personnel. Do not stay under hoisted load!
5.2. STORAGE
The machines can be stored in two ways:

Ordered closely side by side on a suitable area.
Attention!
If machines are transported set on slides only and covered with
polyethylene film, they should be stored in closed rooms.
5.3. UNPACKING.
Start unpacking the machine, transported in crate by removing the ceiling of the
packing, then remove the side wall next to the apron and the feed box, the two face
walls in sequence and finally the second side wall. Remove the polyethylene
covering the machine.
Immediately after unpacking, check the machine condition, the availability of the
units, specified in the packing list of the manual. In case of missing items and faults,
immediately inform supplier’s company
Release machine from the slide by unscrewing the bolts, which tighten the legs
to the slide.
5.4. LIFTING AND HANDLING.
When unloading the lathe from the transport vehicle, it is recommendable to

first unload the machine together with the wooden slide.
That is done with a suitable for the purpose equipment, which should be chosen
in consideration of the machine weight. It is recommendable to unload on a ramp. Lift
and move the unpacked machine by crane or manually – with the help of ropes and
levers, which are set under the legs of the machine and used as rollers. No sharp
pushing and hammering is allowed in either case, because they may lead to damage
reducing the operating accuracy of the machine.
When removing the machine from the wooden slide, set it free by unscrewing
the pins it is fastened with. Remove rear shield from the lathe. Set saddle and rests
at the rear end of bed. Move apron as far back as possible, however in a way
preventing it from hampering the hoisting ropes. Fasten saddle and steady rest to the
bed.
No matter what the machine length is, hang it on the rope or chain, to be used
to lift it by the crane in the following way: set rods of non-hardened steel with
diameter 50 mm and length greater than the leg width in special holes in the front
and rear leg across the machine bed. Hang the rope on both sides of the rods (Fig.
5.4.1.). Set pads of suitable material in places where paint damage may occur. When
choosing ropes, chains and lifting equipment take into consideration the weight of the
machine.
Setting of the machine, prepared for lifting by ropes or chains, is shown in
Fig.5.4.1.
Attention!
Crane and rope loading capacity to conform to machine weight!
Do not stay under lifted load!

Ст
Fig.5.4.1.
5.5. REMOVAL OF CONSERVATION STUFF
When packing all outer not painted surfaces of the machine are covered with
protection rust prevention coating.
Before placing the machine on its allocated working place, clean it thoroughly
from the protection coating. Cleaning is done first mechanically – using wooden
spade, then the lubricated surfaces are cleaned with mineral alcohol or aliphatic
petrol dissolver. Gasoline or other easily inflammable liquids, which may form
vapours in the electric equipment and cause fire when the electric power is switched
on may not be used.
Do not use hard objects or dissolvers, which may damage the metal surfaces
or paint. Dry and lubricate cleaned surfaces with a thin film of machine oil or grease.
Attention!
Smoking and usage of fire at a distance of less than 10m from the
machine is strictly forbidden!
In case of improper use of cleaning agents they may enter into
contact with the eyes or the skin.
Machine cleaning should be carried out in rooms with sufficient flow
of fresh air!
5.6. POSITIONING, FOUNDATION AND LEVELING
To achieve faultless operation of the machine and maintain its accuracy, it is

necessary to install it on a foundation, prepared in advance, and to level it well.
Foundation is cast of concrete in accordance with the foundation plan, shown in
Fig. 5.6.1.
The outer broken line shows the dimensions of the working area, required for
the normal operation and servicing of the machine. The foundation is cast of concrete
with a thickness of not less than 300 mm. The dimensions of the foundation bolt
holes are 50х50х300mm.
If the machine is installed in a place of high vibration or hammering from other
machines (hammers, presses, etc.), enclose the foundation with vibration insulation
material.
Level the machine in the following way:
Place steel leveling straps on the precast and hardened foundation next to all
holes for foundation bolts.
Place the machine so that its leveling screws are set on the leveling straps and
the foundation bolts enter their respective holes. Carry out the initial leveling of the
machine by tightening the leveling bolts by checking horizontality of guideways with
the help of a precise 0.02/1000mm level along and across the machine axis for
compliance with the values shown in the geometric accuracy norms.
Cast cement grout of 1:3 cement/sand ratio on foundation bolts and area under
machine feet.
Once the grout has hardened, tighten foundation bolt nuts carefully by
tightening them up evenly.
Check the machine leveling after you have tightened the nuts, and correct, if
necessary, with the help of the leveling bolts.
Along with above, the long year operation of our lathes has proved that they are
capable of operating with sufficient stability and accuracy, even if not installed on
special foundations. In cases when production or conditions make it necessary to
move the machine from one place to another frequently, this is particularly
convenient for the operation of these lathes. In such case it is sufficient to place the
machine on a firm surface (e.g. concrete plate) and level it with the help of the
leveling straps and bolts or to install it on vibration insulation supports and level it.
Check and eventually correct horizontality in both directions of the machine set
on foundation at first every three months. For machines, which are not installed on
foundations, carry out such checks more frequently depending on the type of floor
the machine is set on.
Preservation of machine accuracy for a longer time depends on whether or not
above rule is observed.
РМС 750 1000 1500

A 1018 1268 1768
B 2923 3173 3673
Note: All dimensions in mm

Broken line shows the working zone
* Distance between centers
Fig.5.6.1- Foundation plan
5.7. CONNECTION TO THE ELECTRIC MAINS
The machine should be connected to the electric mains by a qualified,

authorized specialist, who has made himself familiar with chapter 17 of this
manual.
When connecting the machine to the electric mains make sure to observe the
following instructions:
- The electrical data of the machine to correspond to the data of the supply
mains;
- Connect the machine to the electric mains without slow acting fuse;
- Use supply cable of a cross section suitable for the capacity of the machine
and the distance to the supply panel. Supply cable to be mechanically well protected
at machine entry, (e.g. by a pipe) to avoid accidents.
- Earth the machine to the neutral in a reliable way, by using a four wire supply
cable for this purpose. This is applicable for mains with directly earthed star center.
For countries where low voltage electrical mains have insulated star center, the
machine is earthed in accordance with the regulations in effect there. Neutral
earthing (or) earthing for mains with insulated star center is done by using the entry
neutral (earthing) plate where entry neutral (earthing) wire is connected with the
required care and attention.
- Inspect carefully the electrical installation, the electric panel and the electric
controls before having connected the supply voltage. In case of faults, resulting from
transport, carry out the necessary repair by using the service offices of maker’s
factory according to the regulations in effect for implementation of new equipment.
- In cases where wetness of electric motors and drop down of their electric
insulation resistance below the admissible limit is found, dry up the electric motors
until their electric insulation resistance is restored; after connecting the supply
voltage, check for absence of dangerous electric potentials of machine body against
earth. Then carry out repeated performance tests of the electric controls. Perform the
tests in accordance with procedure, stated in the next chapter “Actions”.
Actions
Machine operation is checked on the basis of the main electric diagram.

Connect supply voltage with main switch MS.
When the voltage is connected, signal lamp HL, located on the machine control
panel goes on.
Start up main motor with by means of button SB1.
Connect coolant pump motor by two positional switch SB2 –“on/off”. Start up
rapid traverse motor by pressing button SB3, which is located on the carriage, and
stop it by releasing the same button.
Switch on local illumination lamp by button SB4.
5.8. COMMISSIONING INTO OPERATION.
Before initial commissioning into operation or after a prolonged period of

idleness, a renewed inspection of the machine and cleaning of all its mechanisms is
carried out. Oils in gear box and apron are checked, guideways of bed, carriage
slides, tailstock, lead screw are lubricated according to the instructions for lubrication.
Movement of all mechanism is tested manually. It should be easy and
troublefree. Machine controls are also checked for proper functioning.
Attention!
Tests to be carried out with main switch off and secured against
accidental switching (eventual locking).
Fill tank with coolant.

Test on idle run in sequence gear box, feed box and carriage, by gradually
passing from lowest to highest revolutions and feeds. Pay special attention to the
engagement of gears. This is achieved by rotating handles to their fixed position.
Attention!
Pay attention to the proper engagement of gears. This is attained by
rotating the handles to their fixed position.
When testing the mechanisms, the functioning of the lubrication system should
be controlled. Check oil supply from the pumps of gear box and feed box and of
apron.
Test “stop” button operation and emergency stop pedal in case machine has
been ordered with emergency stop pedal.
Attention!
Change of speed is carried out when the machine is in standstill, and
change of feeds is allowed also when spindle rotates at up to 100
rev/min.
There is a potential danger that gear teeth may break.
Then test cooling system operation by pressing the start button of the system.
After one hour operation of the machine check the oil level and replenish, if
necessary.
Check V-belt stretching after the machine has operated for two working shifts
under load.
5.9. EMERGENCY STOP.
It may occur when:

- “General stop”, item 27, Fig. 6.1. button is pressed.
- Side cover is opened;
- Chuck guard is lifted;
- Emergency stop pedal is pressed.
Procedure when exiting from emergency stop mode:
- Close side cover, if opened;
- Remove protection shield, if lifted;
- Release general stop, or stop pedal.
6. TECHNICAL DESCRIPTION
6.1. MAIN UNITS AND CONTROLS OF THE MACHINE (Fig. 6.1.)
1. Bed
2. Legs
3. Gear box
4. Feed box
5. Apron
6. Lower carriage
7. Upper carriage
8. Tailstock
9. Drive
10. Control shaft
11. Quadrant
12. Tool post
13. Dead stop
14. Quadrant cover
15. Shields
16. Rests – complete set
17. Electric panel
18. Switching handle for “left” and “right” thread
19. Coolant system
20. Lighting installation
21. Control lever for connecting “forward” and “reverse” direction of rotation
or disconnecting of spindle
23. Handle for selecting “normal” or “increased” thread and feed pitch
24. Speed range selection handle
26. Subrange selection handle
27. “Stop” (emergency” button
28. Handle for selecting pitch for feed or threads
29. Handle for selecting pitch for feed or threads
30. Handle for connecting the movement to feed shaft or lead screw
31. Handle for connecting and disconnecting of split nut
32. Control lever for longitudinal and transverse movements
33. Handwheel for longitudinal movement
34. Handwheel for manual transverse feed
35. Handwheel for manual movement of upper carriage
36. Vernier for longitudinal movement measuring
37. Handwheel for manual movement of quill
38. Handle for quill lock
39. Handle for tailstock lock
40. Main switch
41. Rapid traverse on/off button
43. Guideways lubrication button
Fig.6.1
Fig.6.1
6.2. KINEMATIC DIAGRAM (Fig.6.2)
Fig.6.2
6.3. GENERAL INFORMATION ABOUT MAIN UNITS
6.3.1. BED
The Bed is basic structural part of the machine provided by gap. The bed
length is available, either Distance between centers: 750mm , 1000mm, 1500 mm .
The bed is made of an iron casting, shaped in a way permitting the efficient chip
and coolant removal to the chip collecting pan.
Bed guideways are surface hardened and precise ground.
6.3.2. GEAR BOX

The gear box is mounted on the bed and houses the complete main drive. It is
driven directly by the main motor by means of a belt transmission.
The C400TM universal lathe has 12 speed ranges and speeds vary from 50 to
2240 revolutions/min.
The kinematic diagram of the machine is shown in Fig. 6.2.
Speed diagram is shown in Fig. 6.3.2.1.
Forward and reverse rotation of spindle is accomplished by changing main
motor direction of rotation.
Precise bearings are used for spindle bearing.
To change spindle rotation direction a handle 21 in Fig. 6.1. is used.
6.3.3. QUILL.
The Quadrant transmits the motion from Gearbox to Feed box through gears.
It is located in the Quadrant box on machine face part and is closed by a door. The
Quadrant is a main unit for Multiple thread cutting and shift from metric/inch threads
to DP threads.
Attention!
Quadrant box door may be only open when the machine main motor is
standstill by Emergency stop Push button activated.
Fig.6.3.2.1
6.3.4. FEED BOX

The Feed box is consists of a multiplexing mechanism (a group of four gear
drives, a main mechanism with eight drive gears and a distributing mechanism.
The Feed box lubricating is by oil splashing.
The Feed box kinematics is shown on Fig. 6.2
6.3.5. APRON
The apron is mounted on the carriage plate in a fixed way. It houses the
mechanisms serving to connect the longitudinal and transverse self-moving devices,
the mechanisms for engaging the nut to the lead screw, the overload protection
mechanism and the locking device, which does not allow simultaneous connection of
nut to lead screw and automatic feed.
The control panel of the machine is mounted on the apron.
The apron kinematic diagram can be seen in the general kinematic diagram of
the machine in Fig. 6.2.
6.3.6. LOWER CARRIAGE

The Lower carriage is a part of the Carriage unit and its basic components are
Carriage base plate and Lower slide.
The Carriage base plate is mounted on the machine Bed guideways and all
other parts are mounted on the Carriage base plate. The Lower slide crosswise
motion is along the Carriage base plate guideways driven manually or automatically
(Feed motion or Rapid traverse).
Lower carriage longitudinal motion can be performed by one of the following
ways:
• Feed Drive Motion: by Feed box mechanisms, Lead shaft and the Apron
mechanism;
• Working stroke – by mechanisms from feed box, lead screw and apron nut.
• Rapid Traverse: by the Rapid Traverse Motor and Apron mechanism;
• Manually: by the Handwheel and Apron mechanism.
Lower carriage crosswise motion can be performed by one of the following
ways:
• Feed Drive Motion: by Feed box mechanisms, Lead shaft, Apron mechanism,
the Cross screw and its Nut;
• Manually: by Handweell mounted on the Cross screw, the Cross screw and its
Nut.
When necessary, the Carriage base plate can be fixed to machine guideways
by two clamping plates and two screws.
6.3.7. UPPER CARRIAGE

The upper carriage is a unit belonging to the carriage group. Its main
components are cross slide, upper slide and tool post.
For short taper surface manual turning the cross slide may rotate against the
lower slide in both directions under 900 and get fixed in the desired position by means
of four special bolts with nuts. The upper slide on which a four position tool post is
mounted is moved manually along the cross slide guides by means of a flywheel.
Thus the cutting tool can get a longitudinal or transverse motion.
6.3.8. TAILSTOCK
The tailstock is mounted on the machine bed guideways and clamped on them.
The quill is set on bearings in tailstock body. The front end of the quill has a taper
hole, in which a center or other tools are fixed. The quill can be moved axially by
means of handwheel 37 (Fig.6.1.) and locked in the desired position by lever 38.
Tailstock is locked to the bed by means of the quick-clamping handle 39 (Fig. 6.1.).
To machine long taper surfaces of small taper angle, it is possible to displace
tailstock 8 crosswise by using screw 26 (Fig. 6.1.).
1. Live center is knocked out by means of the quill travel screw.

2. The quill has a hole for a wedge, with which flat tip shank tools to DIN 229
are knocked out.
7. ADDITIONAL ACCESSORIES
7.1. CLAMPING AND DRIVING DEVICES
The machine is completed upon client’s request with different clamping and
driving devices (please, refer to table 2.3 – additional accessories). Their clamping to
the machine and the operation with them are shown in chapter 12 of this manual.
7.2. RESTS
The lathe is completed with a follower and a steady rest.

Both types are equipped with sliding quills as a standard execution. The steady
rest is clamped in a fixed way to the bed guideways, and the follower rest is clamped
to the carriage plate.
Rests should be clamped in a reliable way and clamping should be tested, that
of the steady rest in particular.
Upon request the steady rest can be completed with roller quills.
7.3. TAPER ATTACHMENT.
The taper turning attachment is an additional accessory of the lathe used to

machine internal and outer taper surfaces with a length of up to 250 mm and a
maximum angle of ± 100. It is mounted on the carriage plate. It is designed to ensure
a high accuracy of the machined surfaces, and convenient and reliable operation.
7.4. THREAD INDICATOR
Upon client’s request the lathe may be completed additionally with a device to
re-enter the thread pitch “thread chasing dial” – thread indicator.
The indicator is mounted on the apron, not engaged to the lead screw, for
metric or inch execution of the lathe respectively. It is used to re-enter the pitch of the
machined thread (e.g. for a thread machined in several passes)
Attention!
If the machine has protection of the screw and the shaft, the thread
indicator can be used only if protection is removed.
8. TECHNICAL SERVICING
8.1. GENERAL INSTRUCTIONS
The correct operation and servicing of the machine is a guarantee to preserve

its accuracy and improve its reliability.
The machine is cleaned regularly and lubricated in accordance with the
lubrication plan (Fig.9.1).
All mechanisms and units are adjusted in accordance with the instructions of
this manual.
8.2. DAILY SERVICING
The following should be checked prior to operation:

- oil level in gear box;
- oil level in feed box;
- oil level in apron.
It is necessary to clean the working zone, the three jaw chuck, the four position
tool post and the quill on a daily basis.
Attention!
Cleaning of machine is done using soft cloth, usage of compressed
air is not allowed.
8.3. WEEKLY SERVICING
At the end of the working week the machine, the working zone and the apron
should be cleaned thoroughly.
8.4. MONTHLY SERVICING
Change of coolant and cleaning of tank. Check of rapid traverse belt

tensioning.
8.5. ANNUAL SERVICING
Check clearance of carriage cross slide and longitudinal slide and tighten
wedges, if necessary. The clearance, measured with a 0.03mm clearance meter,
should not enter between contact surfaces at a depth, greater than 10mm.
Check for availability of axial clearance in transversal screw.
Check for availability of axial clearance, radial and axial hammering of the
spindle in accordance with the geometric accuracy protocol.
9. LUBRICATION
It is of great importance for the correct and trouble free operation of the
machine is to follow regular lubrication of the machine parts using recommended
lubricants.
We recommend to you as follows:
• Regular lubrication and oil change
• Do not mix different types of oils and greases; Use recommended brand
names, only
• Clean the machine parts with soft cloth, only
Attention!
- Never use pressurized air for machine cleaning
- Do not use aggressive or volatile liquids when wash the boxes
Lubrication of gear box
The gear box is lubricated by dispersing. The oil is poured into the box
through a plug.
The oil in the gear box is to be changed for the first time after 10-15 days of
operation, the second time – after 20-30 days of operation and thereafter at every 2-
3 months.
When changing the oil, the used oil should be drained through plugs which are
located in the base of the gear box bed /at the side of the quadrant/. The box should
be washed with pure naphtha and the fresh oil should be filtered through strainers
before pouring it into the box.
Lubrication of feed box
Feed box mechanisms lubrication is by oil splashing.

Feed box oil change is made periodically as described for the Gearbox above.
Oil filling plug is provided on the Feed box upper part and on the lower part of
the Feed box a Drain plug is provided.
Quadrant gears lubricating is by grease applied monthly.
Lubrication of apron
Apron mechanisms lubrication is by oil splashing. A plug for oil filling is

provided on Apron left side the oil drain plug is provided on Apron lower part.
A Piston type lubrication pump is mounted in the Apron that continuously
circulates the oil in the Apron.
A piston oil pump is mounted in the apron. In basic position the pump operates
by “flowing together”, i.e. the oil is returned to the apron by the pump through a pipe
line. The oil is changed at the same intervals as that of the gear box.
Control valve 43 (Fig.6.1.1) is built in the apron. It lubricates the front and rear
guideways of the bed, the lead screw and the gears in the apron by being turned
manually.
Lubrication of lead screw and shaft
Lubrication is done by means of control valve 43 in Fig. 6.1.
Lubrication of carriage
Carriage sliding surfaces are daily lubricated with oil through provided
respective Oil nipples.
Lubrication of tailstock
Tailstock Quill and Screw are daily lubricated with Oil through provided
respective Oil nipple.
Lubrication of lead screw bearings and shafts
Rear bearings of lead shaft, lead screw and control shaft are lubricated
manually with grease by means of lubrication grease gun through the respective
oilers.
Lubrication of quadrant
Quadrant gears are lubricated once per week. In case of tropical climate
quadrant gears are greased regularly along their complete surface to protect them
against corrosion.
9.1. LUBRICANTS
Types of oil and grease, which may be used to lubricate different mechanisms
of the lathe are specified in the table below.
Company Lubrication oil Lubrication oil Grease

/country / viscosity viscosity NLGI -Kloisse
32 mm2/s 68 mm2/s
DIN 51502 CL 32 CL 68 K2K-20
ISO 3498 CB 32 AN 68 XM2
Bulgaria MH-M-32 MMO-50 Litea-2
Russia IGP-18 IGP-38 Fiol 2
/machinnoe”L”/ /vretennoe 30/
ESSO NUTO H 32 NUTO H 68 Beacon 2
SHELL Shell Tellus Shell Tellus Shell Avania
Oil C32 Oil C68 Fett R2
CASTROL Hyspin AWS 32 Hyspin AWS 68 Spneerol AP2
9.2. LUBRICATION INSTRUCTIONS

Fig.9.2 below show periods, lubricant type, and method of lubrication for this
machine parts lubrication.
Fig.9.2
10. OPERATING THE MACHINE
The following should be observed when operating the machine:

- Abrupt reversing of main spindle at comparatively high spindle revolutions and
with heavy, already positioned workpieces is not allowed.
- Lubricant should be applied between the workpiece and the support surfaces
of the mounted before that rests at adequate intervals.
- Positioning displacements by using carriage rapid traverse in close proximity
of spindle box and tailstock should be done with adequate attention.
- Using rapid traverse as working feed is not admissible.
- The machine may not be used for correcting operations of workpieces with
random cross section and not straight axis.
- It should be controlled that chip and coolant collecting pan not overflow, in
order to avoid chip and coolant coming out and spilling outside the machine.
- Coolant flow rate should be chosen correctly in order to avoid its intensive
evaporation.
When replacing coolants and lubrication and cooling liquids care should be
taken to prevent them from spilling on and around the machine, and suitable devices
(e.g. funnels or containers with protruding orifice) should be used.
When machining the workpieces, it is recommended to:
- Use cutting tools of suitable cross section and shape in order to achieve one
secure breaking of chips with the purpose of ensuring a good chip removal.
- Use suitable coolant and protection shields, set in working and faultless
condition.
- Safe positioning of workpiece (e.g. in rests).
- Correctly chosen cutting mode (which does not cause vibrations, noise and
unstableness of the machine).
- When operating with long rod materials to use rotating supports for that part
of the workpiece, which protrudes outside the machine, and enclosures of the
dangerous zone.
Attention!
Remove chips piling up on workpiece, clamping device, tool, tool
post and other places on the machine by using a suitable device, and
under no circumstances by hand or by compressed air.
- Wearing loose, long hair, beard, finger rings, wrist watches and
similar is not allowed. Wear only properly closed shoes, suitable for
the requirements of the working place. We recommend wearing of
protection shoes.
- Wear tight-fitting clothes. Loose working jackets and loose arms
may cause danger.
- Wearing gloves when operating the machine is not allowed. PVC
gloves may be worn in exceptional cases with the permission of the
working shift master.
- Before manipulating the clamping devices (universal clamping
device, facing head or center plate with turning dog, wait for the
machine to come to a complete standstill.
10.1. SPEED SELECTION
The desired speed is selected using handles 2, 3 and 4 (Fig. 10.1.). Different
speed values in RPM are marked on disk 1. Speed ranges “red - I” and “green - II”
are marked on disk 1 and they are selected by handle 3. Three speed sub ranges are
selected by handle 2 until some of arrows on disk 1 match to arrow on the main table.
Handle 4 has two fixed position and with it’s, we selects desired speed.
Attention!
Speed change is done only when the machine is in standstill. In case
of danger, use immediately the “Emergency stop” button or the
emergency stop pedal.
Run up of all speed a step is achieved by starting from the lowest ones and
reaching to the maximum ones.
Fig.10.1
10.2. FEED DRIVE
The feed drive of the machine, with the help of which different feeds and
threads are achieved, consists of normal and increased pitch mechanism, housed in
the gear box, the quadrant and the feed box.
The motion to the feed drive is transmitted from the spindle with the help of the
normal or increased pitch mechanism – handle 23 (Fig. 6.1), whereby normal and
increased pitches are attained, depending on the handle position, shown in the main
name plate.
The quadrant is completed with a certain number of gears, which differs for the
metric and the inch execution.
Attention!
Quadrant box door may be only open when the machine main motor is
shat down and actuated Emergency stop push button (red mushroom).
The Feed box consists of multiplication mechanism, selecting mechanism and

mechanism for the kind of thread and distributing of motion to the Lead shaft (for the
feeds) or Lead screw (for the threads).
The various feed rates for the threads to be cut are provided by the Quadrant
and setting the Handles 28, 29, 30 and 18, Fig.6.1 on different positions.
Handle 28 controls the multiplication mechanism and can be set in three
positions.
Handle 29 controls the selecting mechanism and can be set in eight positions.
Handle 30 controls the mechanism for the kind of thread to be cut and motion
distributing to the Lead shaft or Lead screw and can be set in three positions.
Caution: Feeds change is allowable at Spindle speed up to 100 r.p.m.
The Quadrant setting and positions of Handles 28, 29 and 30 positions are
shown on the Thread and Feed rate Diagram plate located on the Gearbox. The
Thread and Feed rate Diagram plates are shown on Fig. 10.2.1 and Fig.10.2.2 (for
metric and inch version, respectively).
The rout of motion transmission from Gearbox through the Quadrant and
through respective mechanisms of the Feed box to lead shaft or to lead screw at
various different threads can be seen on the Kinematics diagram (Fig.6.2).
For automatic feed and right hand thread cutting Handle 18, Fig.6.1 of the
Gearbox should be set on right hand thread position. For left hand thread cutting
should be set on left hand thread position. At this setting an automatic feed for a
general turning operation is not available because the Lead shaft drives the carriage
through a single-direction advancing clutch. By the same reason, when the spindle
rotates in reverse direction and Handle 18 is set on right hand thread position, the
lead shaft does not transmit motion to the Carriage mechanism i.e. when Handle 18
is set on right hand thread position, automatic feed is not available.
Carriage longitudinal and crosswise feeds are provided by the Lead shaft and
Carriage mechanism. The Carriage automatic longitudinal and crosswise feed
motions (both directions) are controlled by Handle 32, Fig.6.1. The direction to which
Handle 32 is positioned corresponds to the direction of Carriage motion.
The Carriage motion when cutting a thread is provided by the Lead screw and
the Carriage Half nut. Handle 31, Fig.6.1controls the Half to Lead screw meshing.
A special protection is provided between the Handle for automatic feed control
32 and the Handle for Half nut meshing 31 so that either of them may be actuated in
a time.
The Carriage rapid traverse is driven by the Lead shaft and a Rapid traverse
motor mounted on the Apron right side.
The Carriage rapid traverse is controlled by positioning the Handle 32 on the
desired direction of the traverse and by pressing the Push button 41 for rapid
traverse motor starts.
Attention!
The machine may not be used for processing rod material sticking
out from the machine.
Attention!
Any modifications to the wrench supplied by the manufacturer with
the faceplate, or the use of another wrench, is strictly forbidden!
Do not use any extensions of the wrench for the faceplate!
Attention!
Use the wrenches supplied or standard wrenches to set-up, maintain
and repair the machine!
Fig.10.2.1
Fig.10.2.2
11. SETTING UP FOR DIFFERENT THREADS AND FEEDS
11.1. MULTISTART THREAD CUTTING
The availability of suitable gears in the prefeed mechanism of gear box provides
the possibility for precise cutting of multistart threads. When handle 23 (Fig.6.1) is in
position for normal pitch, it is possible to cut 2, 3 and 6-start threads, regardless of
the spindle revolutions. When handle 23 is in position increased pitch, 2, 3, 5 and 6-
pitch thread can be cut.
Multi-start thread cutting is done as follows:
The feed drive is set up for thread with thread pitch multiplied by the number of
pitches. We cut the first start of the thread. A disk with graduated figures 0, 2, 3, 5
and 6 is mounted on the rear end of the spindle.
We turn the spindle directly by hand or by a belt pulley so that the “0” figure
comes against the notch on the gear box flange. We disengage the gears from
unilateral force, by turning the spindle slightly in both directions several times and
then bring back again the “0” figure against the notch. No resistance should be felt.
Then we set handle 23 (Fig.6.1) in neutral position. We turn the spindle in the given
direction until the figure, which is equal to the number of starts of the thread being
cut, coincides with the finger. We switch handle 23 in the previous position again and
cut the second start of the thread. This is repeated until all thread pitches are cut.
Attention!
Before setting up the spindle by turning it manually to position,
switch off the main switch and ensure it against accidental switching
on (e.g. locking)
11.2. CUTTING OF TAPER THREAD (BRIGGS THREAD)
Since these kinds of threads are taper they should be cut by a Taper Turning
Attachment (option). For these threads pitches of 11 1/2 TPI and 27 TPI are applied
and 13 1/2 TIP also possible (not shown on the Diagram for Feed rates and
Threads). Since the threads are very short to cut them any setting shown on the
Diagram of threads may be applied whereat a negligible error may occurs as
following:
• For cutting thread of a pitch 27 TPI = 0,940 apply setting for metric thread of
pitch 0,9375 whereat resulted relative error = 0,00345 or the error along 10
mm of the thread is 0,0345 mm (0,00136 ”);
• For cutting thread of a pitch 11 1/2 TPI apply setting for DP36 whereat
resulted relative error = 0,00302 or the error along 10 mm of the thread is
0,0302 mm (0,00119 ”);
• For cutting thread of a pitch 13 1/2 TPI apply setting for metric thread of pitch
1,875 whereat resulted relative error = 0,00345 or the error along 10 mm of
the thread is 0,0345 mm (0,0136 ”);
11.3. TURNING
- Turning of short parts in chuck:

The workpiece is clamped securely in the chuck, which is mounted in the front
face of the spindle. Suitable spindle revolutions, and carriage travel, cutting tool of
suitable shape and material are selected depending on machined diameter.
The following operations are possible in this case:
- outer machining;
- drilling of holes and boring of same;
- right and left thread cutting;
- turning of the face of the workpiece;
- cutting.
Attention!
When cutting, do not put your hand under the cut workpiece. You
may injure your hand or get your clothes caught.
- Turning between centers or between chuck and center.

When longer or small diameter workpieces are machined, it is not
recommendable to clamp them only in the chuck, because the workpiece may get
deformed during machining or bend when rotated. Heavier and long workpieces may
drop from the chuck, which can lead to heavy injury. Such workpieces should be
machined either between two centers (dead center - clamped in the spindle and
rotary center – in the tailstock) or clamped in a chuck and supported by a rotary
center. To do above workpiece faces should be prepared in advance – a suitable
center hole is drilled in them (the center hole diameter is selected depending on the
workpiece diameter).
The following machining processes can be performed:
- external machining of cylindrical surfaces;
- cutting of external thread;
Machining of taper surfaces with the help of:
• Upper carriage – it is turned at the necessary angle, and the feed travel is
performed with the help of handle 35 (Fig. 6.1).
• By cross-wise displacement of tailstock. Then a taper surface can be
machined along the complete length of the workpiece. Such type of machining can
be performed only in operation between two centers.
Attention!
In case of operation between centers or between chuck and rotary
center, the tailstock should be clamped securely to the guideways,
and after pressing the rotary center to the workpiece, the quill should
be locked with the help of the handle.
- Drilling of holes
This is done usually with a tool, clamped in the quill taper hole. The feed travel is
performed in two ways:
- By handle 37 (Fig.6.1) on the tailstock, if the drilling hole length is smaller than
the tailstock quill travel. Then the tailstock is securely clamped to the
quideways with the help of handle 39 (Fig.6.1).
- by feed travel of tailstock - in this case it is locked to the carriage by special

plates, mounted on the cross slide of the carriage and the front part of the tailstock
and moved forward with the help of the carriage. At this operation the quill of the
tailstock should be locked by handle 38 (Fig. 6.1.) and the clearance between the
tailstock clamping plate and the bed should be minimum, in order to allow a free
travel of the tailstock.
Operations counterboring and reaming of holes can be carried out in the same
way. –Turning of extremely long workpieces.
It is carried out between centers or between chuck and rotary center, whereby
the part is supported in a steady rest. All three quills of the rest are centered in a way
permitting them to lead the workpiece correctly at the rear end, and at the front end
the workpiece is clamped in the spindle chuck. If the workpiece is a solid part, it can
be supported additionally at the rear end by a rotary center.
Machining of long parts of small diameter can be done by additional supporting
by a follower rest, which is mounted on the carriage and moves together with it, and
supports the workpiece at the back in the cutting zone. In this way the workpiece is
protected against deformations during machining and against mistakes in the
dimensions.
Both rests can be completed with ordinary (friction) quills, or with roller quills.
12. CLAMPING AND DRIVING DEVICES

The Spindle nose is in compliance with DIN 55027 / ISO 702-III and USAS B-
5.9D1 / ISO 707-II, Size 6.
Caution: Do not exceed the maximum r.p.m. as marked by the manufacturer on the
chucks or faceplates.
For the installation of the Chucking unit Fig.12.1, turn Bayonet disk 1 is in
direction opposite to spindle forward rotation so that Nuts 2 go through the two-step
Slots of the Bayonet disk. Fit the Chucking unit to the spindle taper so that the
mounting bolts with nuts can go through the spindle holes and Round sleeve 5 goes
into the respective opening of the Chucking equipment. Then, turn Bayonet disk to
the utmost reverse direction to tighten Nuts 2.
To remove the Chucking unit loose Nuts 2 of about 1/2 turn then turn Bayonet
disk 1 so that it widen slots face to nuts.
For the installation of the Chucking equipment Fig.12.2, set Cams 2 that are
radial located on the Spindle, on zero position (The marking on the cam should
corresponds to that on the spindle).
Fit the Chucking equipment to the spindle taper so that Studs 4 go through
spindle holes.
Tighten Cams 2 to clockwise direction.
To remove the Chucking unit set the lowest speed step and the cams should
be in zero position.
Attention!
During installation or removing of a Chucking unit it is very important to
avoid any shocks to spindle, machine bed and the chucking unit itself.
Fig.12.1
Fig.12.2
Clamping of workpieces between centers (Fig.12.3)
When machining workpieces between centers the universal chuck is removed.

The drive plate is mounted on the spindle. Turning dog 4 is supported on drive finger
1. Adapter sleeve 2 and support center 3 are rammed into the taper hole. The torque,
needed to perform the technological process, is transmitted via finger 1 and dog 4.
Attention!
- Working with a dead center in tailstock is strictly forbidden.
- When working with a non-selfcentering chuck special attention
should be paid not to touch the rotating chuck!
- Switch off the main switch and secure against accidental switching
(eventual locking) before removing or setting the clamping device.
Fig.12.3
13. WORKING WITH ADDITIONAL ACCESSORIES

13.1. THREAD INDICATOR FOR PITCH RE-ENTERING (Fig.13.1.1 and Fig.13.1.2)
This option provides thread pitch repeatable accuracy when cutting threads
having pitches as shown on the Table 1. The Thread dial is fixed on Apron left side
by two Screws 4.
Table 1 is fixed on the Thread dial body.
To engage the Thread dial to the Lead screw, turn Arm 9 clockwise by Eccentric
3. To disengage it turns Arm 9 counterclockwise.
On the Thread dial (Metric version), Fig.13.1.1 are provided two scales: 1; 2; 7;
and 1; 4. Either of scales can be select by longitudinal movement of Part 10 so that
selected position to be fixed by Spring 12 and Ball 11.
On the Thread dial (Inch version), Fig.13.1.2 is provided one scale: 1; 2; 4; 5; 10;
20.
The digit 1 is not marked on the scales for it corresponds to any one notch of the
scales.
Setting the Thread dial for operation:
1. Set the lathe for cutting thread of a pitch shown on the Table
2. Position the Carriage for the first cut and engage the Half-nut to the
Lead screw
3. Reset the Thread dial, i.e. set the number that correspond to selected
pitch towards the pointer 5
4. Engage the Thread dial
5. Cut the first start, disengage the Carriage Half-nut and move the
Carriage on Rapid traverse to be ready for the second start
6. Engage the Carriage Half-nut by displacement the Carriage so that the
number corresponds to the pitch stands towards the Pointer and cut the
second start
7. Repeat steps 5 and 6 above as required to complete the thread
8. Upon thread completion disengage the Thread dial
Fig.13.1.1
Fig.13.1.2
13.2. TAPER ATTACHMENT (Fig.13.2.1 and Fig.13.2.2)

The Taper turning attachment is available as an option with this machine. The
application of this option is for turning of outer and inner taper surfaces of length up
to 250 mm and degree of the slope up to + 10o.
Setting the attachment for operation:
• Position the Bracket 26 on a desired position along the machine rear guideway
and fixed it by Bolt 28 and Plate 27. Tighten Bolt 25 by Nuts 24.
• Bu turning Nut 41 the Bolt 25 is tighten to Slide 2 of the attachment
• Loose Screws 14
• By the Screw 17 turn the Guider 40 to the angle desired that is indicated on
Scale 20
• Tighten Screws 14
Adjusted by above procedure attachment should corresponds to the following
requirements:
• The workpiece cylindrical part at the beginning of the slope to be no more than
8 mm, without eliminated clearances. Angle deviation no more than + 5o
• The clearance between Bracket 1 and Slide 2 should be adjusted same way
as described for the Lower slide.
• The clearance between Slider 38 and Guider 40 should be adjusted by loosing
Nut 35 and tighten Screws 36 that press Gib 34 to an extend that required clearance
to be achieve. At this position tighten Nits 35.
Fig.13.2.1
Fig.13.2.2
13.3. EMERGENCY STOP LIMITER (Fig.13.3)

It is designed to limit the longitudinal traverse of the carriage.
When the carriage moves towards the speed box, the screw of the limiter
(pos.3) touches the stop located on the carriage saddle. The carriage stops at
achieving maximal traction effort and the protection device of the feed, located in the
carriage box, is set in operation.
The adjustment of the limiter is made in two steps – its putting on a suitable
place along the work piece through the bolts (pos.5) and fine adjustment of the
dimension through bolt (pos.3) and counter nut (pos.4).
Attention!
It is not allowed to use the longitudinal brake-limiter when threading..
Attention!
Use the wrench supplied with the machine or a standard wrench to
adjust the restrictor!
Fig.13.3
13.4. RESTS (Fig.13.4.1 and Fig.13.4.2)
Follow Rest and Steady Rest are available as options with this machine. The
options are applied as workpiece extra supporting devices when necessary.
The Follow Rest, Fig.13.4.1 is fixed to the Carriage base part by Bolts 12. To
position the workpece in the rest loose bolts 9 by 1-2 turns then, by handles 2 and
Screws 6 move the Quills 7 towards the workpiece body as much as the points 10 go
in contact with workpiece surface.
In this position fixed the quills by Bolts 9
The Follow rest application is for supporting relatively bigger in length and
smaller in diameter workpieces.
The supporting capacity of the rest is for workpiece diameter from 10mm to
80mm.
Fig.13.4.1
The Steady Rest, Fig.13.4.2 installation on the machine bed quideways is by

Plate 16, Bolt 15 and Nut 13. The unit is installed on a preliminary decided position
along the machine bed. To support a workpiece in the rest loose Bolts 8 1-2 turns
then, withdraw the Quills 9 withdraw to utmost outer position. The Steady Rest upper
part should be unclamped from the base by loosing Screw 11 and opened backward.
After position the workpiece within the rest close the upper part and tighten it
to the rest base by Screw 11.
Drive the Quills 9 towards the workpiece body as much as the Points 10 go in
contact to the workpiece surface. Fix the quills by tighten Bolts 8.
This unit also can be delivered with roller quills if ordered.
The Steady Rest is applied for supporting workpieces of heavy weight and of
large diameter.
The supporting capacity of the unit is for workpiece diameters from 10mm to
100mm.
Caution: It is not allowed to Support workpieces by rest having rough (not

machined) surface.
Fig.13.4.2
14. COOLING SYSTEM (Fig. 14.1)

Machine Coolant system provides cooling liquid directly to tool cutting zone.
Coolant liquid flow is delivered to the cutting tool zone by a Motor-pump 1
that sucked the liquid from Coolant tank 2 and through hose 3 the liquid is delivered
to flexible tubing located on the Carriage. Desired flow rate can be controlled by
Valve 4.
Used coolant liquid is directly returned from the collecting basin 5 to Coolant
tank 2.
The Motor-pump 1 On/Off control is by a two-position Switch located on
machine Control panel. It is recommended to turn off the coolant Motor-pump when
Valve 4 is closed.
Before and after using the Coolant liquid clean and lubricate the machine
metal surfaces, which may be rusted from the coolant liquid. Use Coolant liquids that
are not corrosive.
When Coolant system is found faulty (e.g. abrupt flow rate loss or fail to
deliver liquid) check to find the cause and remedy. Often, this occurs when the
Coolant system is not regularly cleaned.
When the Coolant system is often in use it is recommended to clean the
system once per six months. The coolant tank 2 should be cleaned once a week and
the coolant liquid quality should be periodically analyzed.
Coolant liquid should be selected in compliance with material to be cut,
cutting conditions and to be free of hazards for the operator and environment.
Attention!
Avoid contact of coolant liquid with the skin and strictly observe
manufacturer health and safety precautions.
Fig.14.1
15. ADJUSTING OF MECHANISMS

All machine mechanisms are factory adjusted and tested before shipment. As
a result of long time of operation however, the parts and devices of the machine are
subject to normal wear. Therefore, adjustments and setting of parts and devises are
required. Also, adjustments are required after repair work.
Attention!
Before proceeding with the adjusting switch off the main switch and
ensure it against accidental switching (e.g. locking)!
15.1. GEAR BOX CLUTCH ADJUSTMENT (FIG.15.1)

Adjusting is done with removed cover of gear box and disconnected clutch.
Adjusting nut 9 is released by pulling out and turning at 900 finger 10 of fixing stud 7,
whereby pressing disk 16 is detached from the nut. Adjusting nut 9 is turned to the
respective notch, to a predetermined clearance between disks, fixing stud 7 is
returned again to place by setting upright finger 10. Nut 9 is turned until fixing stud 7
enters the hole of disk 16, and then finger 10 is set back in its seat.
The clutch should be able to transmit the full power without slipping of disks,
and it may not heat up due to friction in disconnected position.
After a running in period of the clutch, a repeated adjusting is undertaken in
order to set the torque it should transmit.
Fig.15.1
15.2. GEAR BOX STRAP BRAKE ADJUSTMENT (FIG.15.2)

The brake is adjusted when in case of disconnected clutch it does not ensure
spindle stop in 5 to 6 seconds, without chuck at maximum revolutions. The adjusting
is carried out as follows:
- gear box cover is removed;
- screw item 2 is loosened;
- nut 1 is turned until the excess gap between strap 3 and drum 4 is removed;
- screw 2 is screwed up.
Attention!
In case of long time operation the lining of strap brake wears out. The
lining thickness should be 0.5mm more than the rivets it is fastened
with, otherwise the lining should be replaced with a new one.
The drum may jam and make stopping impossible!
Fig.15.2
15.3. ADJUSTMENT OF BEARING CLEARANCE OF SPINDLE

Since the spindle bearings are precise components and are factory adjusted
during spindle assembly using special equipment no any adjustment is required
during machine operation at the end user.
Should any spindle bearing replacement is required it is strictly recommended
to contact the machine manufacturer.
Attention!
In case a clearance in the bearings has become larger, it should be
adjusted! Vibrations may occur!
To do this adjustment or to replace the spindle bearings, use the help
of an authorized service!
15.4. BELT TENSIONING (FIG.15.4)

They are tensioned in the following way:
- the back cover of the leg under the gear box is removed;
- screw 1, which holds plate 2, is loosened;
- lower nut 3 is unscrewed, and upper nut 4 is screwed up. To check the
tensioning, the belts are pressed down in the middle with a force of 10 to 15 kg. Their
sagging should be 20 to 25 mm;
- nuts 3 and 4 are screwed up facing each other;
- bolt 1 is tightened;
- the back cover of the leg is set in place.
Attention!
V-belts are set by hand. Mounting them by force using any tools
whatsoever is not allowed. Completing new belts with used ones is
not allowed – vibrations may occur!
Fig.15.4
15.5. LEAD SCREW AXIAL CLEARANCE ADJUSTMENT(FIG.15.5)
• Remove the cover from the feed-gear box;

• By using screwdriver put in an upright direction the tooth of the engaging
pulley 2 to release the nut 3 ;
• By tightening the nut 3, the required tighteness at the axial bearings 5, is
achieved ;
• Engage the nut 3 by folding the tooth towards the nut wall;
• Put the cover of the feed gear-box.
Fig.15.5
15.6. SETTING OF SHEAR PIN ON LEAD SCREW (FIG.15.5)

The safety pin 1 of the leadscrew is cut off and the power circuit of the feed
gear box is disengaged. In this case the broken pin should be replaced with a new
one. Two spare cut-off pins are supplied together with the spare parts and
accessories.
• Remove the safety wire 4 from the cut-off pin 1;
• Pull-out the two halves from the cut-off pin;
• Then replace the broken pin with a new one and fasten it with the safety
wire.
Attention!
Replacement of safety pin with a pin of a different configuration is not
allowed – machine may get overloaded!
15.7. ADJUSTING OF CROSS SLIDE SAFETY CLUTCH (FIG.15.7)

This device stops the carriages movement when an excessive load occurs.
To adjust this device, first remove Plug 1.
Tightening of Screw 2 shrinks Spring 2 and increase its resistance. Thus, the
Apron protective device shall stop the motion to the Apron at a higher draw force.
Vice verse, loosing Screw 2 shall result stop the motion to the Apron at lower
draw force.
Fig.15.7
15.8. ADJUSTING THE CLEARANCE OF THE NUTS AND THE SCREW OF THE
CROSS SLIDE (FIG.15.8)
Adjustment of the clearance between the Cross screw and Lower carriage
nut is as following:
• Remove Cap 3, located on Lower carriage upper side to access Nut 1
• Push Pin 2 which fix Nut 1 until loose the nut then tighten Nut 1 until it
is fixed by the other Pin.
• Press the second Pin and tighten Nut 1 until it is fixed by the first Pin.
Repeat the procedure as necessary to obtain required clearance in the screw
joint (1 unit of the Vernier).
Fig.15.8
15.9. ADJUSTMENT OF THE CLEARANCE BETWEEN THE BODY GUIDEWAYS

AND THE APRON PLATE (FIG.15.9.1 and (FIG.15.9.2 )
Adjustment of the clearance from the side of the “v”- body guideways
(See Figure 15.9.1)
• Loosen the screw 1 to release the hub 2;
• The plane “А” of the hub should be adjusted to obtain the required
clearance between 2 and the lower plane of the body guideway, at a tighten position
of the hub 2 by crews 1;
Fig.15.9.1. Adjustment of the clearance from the side of the “V” guideway
Adjustment of the clearance from the side of the “flat guideway”

(see figure 15.9.2)
• Release the counter-nut 3;
• Tighten the nuts 4 to obtain the required clearance between the hub 5 and
the lower plane of the body guideways;
• Tighten the counter-nuts 3 till obtain the required clearance;
Fig.15.9.2. Adjustment of the clearance from the side of the flat guideway
Adjustment control
• If turn the flywheel hand, the apron should moved smoothly and without
any difficulties in a longitudinal direction.
15.10. ADJUSTING THE CLEARANCE BETWEEN CROSS SLIDE AND

CARRIAGE PLATE (FIG.15.10 )
The adjustment of the clearance between the contact surfaces of the lower
slide 1 and the apron plate 2 is made by means of the pin 3.
The clearance between the guideways of the upper slide and crossed apron
is adjusted in the same way.
• To release the pin 3, loose the fixing screw 4 from the rear side of the
slide;
• Tighten the screw 5 till the required clearance is obtained;
• Then fixed the pin 3 by tightening of the fixing screw 4.
Fig.15.10. Adjustment of the clearance between the lower slide and apron plate
Adjustment control
• The clearance between the surfaces under fraction should be less then
0,03 mm, if checked by gauge;
• The travel should be smooth and without any difficulties.
Attention!
The untimely adjusting of the clearance in the carriage may lead to
vibrations!
15.11. ADJUSTING OF TAILSTOCK FOR CYLINDRICAL AND TAPER SURFACE

TURNING (Fig.15.11.1 and Fig.15.11.2)
For turning a workpieces having long taper surfaces the Tailstock upper part
should be crosswise displaced in relation to the base part.
Tailstock 1 crosswise displacement in relation to Base 2 is as following:
• Unclamp Shim 3 in relation to machine Bed by Handle 39, Fig.6.1
• Loose Bolt joint 4
• To displace the Tailstock towards the front or rear guideway Screw 5 should
be screw in or screw out, respectively.
• Scale 6 indicates the value of displacement (one graduation equal to 1 mm)
• Tighten Bolt 4
• Clamp the Tailstock to machine Bed guideways by Handle 39, Fig.6.1.
Warning: After completing the work, return the tailstock to its initial position,
by checking and ensuring the correct coaxiality between head stock and tailstock with
the help of a mandrel and indicator.
Fig.15.11.1.
Fig.15.11.2.
Attention!
In case the tailstock is not securely clamped the workpiece may fly
out during operation.
15.12. ADJUSTING OF GEAR BOX FOR CYLINDRICAL SURFACE TURNING

(Fig.15.12)
The adjustment is done in the following way:

Loosen the screws and nuts (of the pin), which secure the gearbox to the bed.
There are two adjusting screws 1 and 2 (Fig.15.12) at the back of the bed, which rest
on the gearbox casing. At the front of the bed, under the gearbox a fixed axle is
mounted and the gearbox can rotate around it. Depending on the direction you need
to rotate the gearbox in, you should loosen the opposite screw (i.e. item 1) and
tighten screw 2 until the axes of the gear box coincide with the guideways axes. A
measuring mandrel is secured to the gear box and measuring is carried out by a dial,
which is mounted on the carriage. When the measurements taken are satisfactory,
tighten adjusting screw 1 completely, then the screws and the nuts, which secure the
gear box to the bed. Check again, using the dial, whether the desired adjustment is
achieved. This procedure may be repeated until you have achieved the desired
straightness (i.e. cylindrical surface).
Fig.15.12
15.13. ADJUSTMENT THE POSITION OF THE HANDLE FOR SAFETY

HANDWHEEL TURN OFF WHEN CROSS DRIVE IS TURNED ON (Fig.15.13)
The Adjust is as following:

• Turn On the cross drive by Handle 12
• Loose Screw 8 and take out Plug 9
• Loose Screw 7 by 1-2 turns
• Screw in by a screwdriver Screw 10
• Verify if the Cross screw Handle is free. If no, screw in Screw 10 as much as
the Handle is free.
• Tighten Screw 7; replace Plug 9 and Screw 8.
Fig.15.13
15.14. APRON PROTECTION DEVICE (Fig.15.13)

This device stops the carriages movement when an excessive load occurs.
To adjust this device, first remove Plug 1.
Tightening of Screw 2 shrinks Spring 2 and increase its resistance. Thus, the
Apron protective device shall stop the motion to the Apron at a higher draw force.
Vice verse, loosing Screw 2 shall result stop the motion to the Apron at lower
draw force.
16. PROTOCOL OF MACHINE GEOMETRICAL ACCURACY
Lathe
OF NORMAL ACCURACY
DIN
Diameter of rotation up to 800mm 8606
Terms of acceptance
Type: Machine No.

Receiver Order No.
Date: Received by:
16.1. PRELIMINARY EXAMINATIONS
Object of Deviation
№ examination Figure Examination means Examination conditions
Marginal Measured
Machine
setting
а) High precise level. The slide in the middle а)0.01mm а)......mm
in longwise Optical or similar position measured points за L до 500mm. for L up to
direction method. Accessories locate uniformly along the (convex) ……. mm
Local tolerance:
corresponding to the body at even distances 0.02mm
type of guideways за L до 1000mm
а) – put the level on the convex) .........mm
front (resp. on the rear) Local tolerance for L up to
guideway. 0.0075mm на …….. mmm
250mm
If the working
О1 length is over
1000mm, the
admissible
deviation is then
increased by
0.01mm for every
next 1000mm.
(convex)
Local tolerance
0.015mm на
500mm
b) See O1 а) b) – put the level on the b)0.04mm/m b) ............
in crosswise bridge (guide) Change of tilt mm/m
О1
direction It can be also over the cross
or longitudinal slide.
16.2. GEOMETRICAL TESTS

Object of Deviation
№ examination
Figure Examination means Examination conditions
Marginal Measured
G1 Rectitude of the а) L up 1500 mm а)-arbor between centers .Ind. dial а) and b) 0.015mm а) ........mm
slide movement ind. Dial acc to DIN is over the slide. Nose touches the L to 500mm b).........mm
in horizontal 879. arbor in a horizontal plane. The 0.02mm
plane , defined slide is moved long-wisely resp. L above 500mm to
from the axis of
Arbor or guide way the arbor. 1000mm
rotation and the of 300 up 500 mm b)-string fixed to the spindle box, If the processing
top of the tool. length passed over roller to the end body length is above
b) –for all lathe and stretched by a plumb bob. 1000mm, the
lengths. Microscope is on the slide. admissible deviation
String and The string id straightened at the is increased by
microscope, or an cross of microscope in c and d. 0.005mm for each
The slide is moved along the next 1000mm,
optical method. string. without excessing
0.03mm
G2 Parallelism btw Index dial acc. to Put ind. dial on the slide. а) and b) а)........mm
the slide and DIN 879 Meas. nose touches the 0.03mm L up b).......mm
tailstock guides tailstock quill. The quill is in its 1500mm ..........mm
at: Local tolerance ..........mm
а)- horizontal
working position. The slide 0.02mm to 500mm
plane with tailstock are moved along а) and b)
b)-vertical the body. 0.04mm
plane L above 500mm
Local tolerance
0.03mm to 500mm
G3 а)- Shaft play of Index dial acc. to The ind. dial is located: а) 0.01mm а)........mm
the spindle DIN 879 (Auxiliary а)- in spindle shaft b) 0.02mm b).......mm
check facilities) b)- on spindle (including shaft
b)- Motion The spindle is rotating
precision in the
play)
front (end) face
slowly. In case of bearing
plane. play apply force F, defined
by.
G4 Circular Index dial acc. to Locate ind. dial perp. To the 0.01mm ........mm
movement of DIN 879 envelope line of the taper.
the spindle Rotate the spindle slowly. In
taper.
case of bearing play apply
force F, defined by the
manufacturer.
G5 Circular Index dial acc. to The arbor is inside the taper. а)0.01mm а)......mm
movement of DIN 879 The ind. dial touches the b)0.02mm b)......mm
the internal generating line of arbor. for distance of
spindle taper.
а)- by the nose
300mm
b- at distance
of half of max. Test arbor with The spindle is rotating.
rotative dia. Morse shank. Measure in a) then in b)
G6 Parallelism btw Index dial acc. to The arbor id inside the taper, а) 0.15mm at а)
the spindle DIN 879 fixed on pos. “Standard 300mm …......mm
shaft and the deviation from circular in the tool direction b)
slide moving at
a distance of
movement. b) 0.02mm ..…....mm
half of max. Test arbor with at 300 mm
rotative dia. Morse shank. By meas. nose trace in upward direction
а)- in horizontal envelope line of the arbor.
plane
b)- in vertical Move the slide at the meas.
plane length.
The procedure is the same

as in G5.
G7 Parallelism btw Index dial acc. to Ind. dial touches the hidden а) 0.015mm а) ......mm
the tailstock quill DIN 879 quill in: at 100 mm b).......mm
and the slide с. The quill is extracted by 100 in the tool direction
movement.
mm and fixed again. b) 0.02mm
а)- in horizontal The slide is moved till d) at 100 mm
plane Measur. in c), then in d). in upward direction
b)- in vertical
plane
Object of Deviation
№ examination
Figure Examination means Examination conditions
Marginal Measured
G8 Parallelism btw Index dial acc. to The arbor is inside the а) 0.03mm а) ..…...mm
tailstock taper DIN 879 hidden and fixed tail stock at 300mm b) .....mm
and slide quill. in the tool direction
movement.
а)- in horizontal
Test arbor with b) 0.03mm
plane Morse shank. Place ind. dial in с), move at 300 mm in
b)- in vertical the slide along the arbor. upward direction
plane
G9 Equidistance of Index dial acc. to Tailstock and quill are tighten. 0.04mm ..........mm
both centers resp. DIN 879 (tailstock centre is
to the base plane. With ind. dial trace generating higher)
line of the arbor.
Test arbor for
clamping btw Meas. At both ends of arbor.
centers
G10 Parral. Btw the Index dial acc. to Place top slide guides in par. 0.04mm ..........mm
spindle shaft and DIN 879 With the spindle shaft in at 300mm
the top slide horizontal Plane.
movement. Lock the slide.
Test arbor with Put the arbor inside the internal
Morse shank.. taper and guide it to the standard
deviation from circular movement.
The top slide with ind. dial, fixed
to it, is moved along the arbor.
G11 Perpendicularity Index dial acc. to Ind. dial is fixed to the cross slide. 0.02.mm ..........mm
of the spindle DIN 879 at 300mm
shaft towards the Test pulley or guideway are fixed directional error if α ≥
slide movement. to the spindle. 90º
Test pulley or
quideway Move cross slide at........mm
G12 Осево биене на Index dial acc. to The ball, placed in the center hole, 0.015mm ..........mm
водещия винт DIN 879 is traced by the ind. dial. in each direction
The slide is driven by the leads-

Стоманена съчма crew in the both directions.
по DIN 5401
This test may be missed if the
practical test P3 is fulfilled (work
accuracy)
G13 Pitch accuracy Index dial acc. to а)-Place test screw btw centers, а) и b) 0.04mm at а)........mm
DIN 879 ans и trace it with ind.dial. 300mm L up 2000mm b).......mm
а)- achieved at образцов винт meas. At any place. ..........mm
lead screw drive b)-Instead of а) may be applied If the machine length
meas. diagram of the leadscrew is greater then
b)-lead screw b)-Precise meas. before assembling. 2000mm, then the
precision check Device (use nut or admissible deviation is
nut segment) increased by 0.005mm
for each next 1000mm,
without exceeding one
max. admissible
deviation of 0.05mm at
300mm.
Local tolerance
0.015mm at 60mm
measured at any place
16.3. PRACTICAL TESTS

Inspected Conditions of processing and Deviations
№ Figure Check-up instructions
object means of measurements Admissible Measured
P1 Work accuracy at If no any prior agreement, а) – two- or three measur. а) 0.01mm а)......mm
plain turning the producer defines: type points. b) 0.04mm b)......mm
of the tool, material test Max. difference in dia. is a l= 300mm l=.......mm
а) circular
b) cylindrical
workpiece (cast iron or deviation value.
steel), feeds, cutting depth
and speed, etc. b) – difference btw two
turning dia. is a deviation
The workpiece is clamped value
and machined.
d≥da/8
da – largest rotation Micrometer or gauge with
diameter index dial to DIN879
l=0.5 da
P2 Working Clamp test. Workpiece. Lay the quideway over the 0.025mm .........mm
accuracy at On its head there are three turning surface. d=300mm d=.....mm
surfacing circular planes, being surface
machined by one run. Distance btw the quideway should be
and the workpiece is set by concave
Guideway of appr. Length, means of check plates only
check plate (thickness (gauge).
gauge)
d≥0.5 da
l= da/8
Р3 Accuracy of Clamp the workpiece btw. Test method depends on type 0.04mm ........mm
thread pitch The centers and machine of measur. Device. at 300 mm ........mm
it by one run. L up 2000
mm ..............
Start thread cutting at any measured
place of the leadscrew. at any
Accuracy of thread pitch Precise measur. device point.
was controlled by G3. Local
Practical test is fulfilled tolerance
under spec. agreement. 0.015mm
at 60mm
measured
at any
point
17. ELECTRICAL INSTALLATION
17.1. MAIN DATA
The machine is completed with an electrical installation, consisting of a main

electric motor, rapid traverse motor, cooling system motor (provided ordered as extra
option) electric panel, lighting body, electrical controls and connecting cables. The
connecting cables are housed in the machine body, and the electric panel is mounted
in a metal cabinet at the gear box rear side. The electric installation is made for main
motor of 4 kW capacity and supply mains voltage and frequency according to client’s
request. All electric motors are three-phase, asynchronous, with cage rotor.
The control circuit is supplied from a division transformer with secondary
voltage 12V and 24V. The lighting body for local lighting of the machine is supplied
with 12V from the division transformer.
The machine is accompanied with shipping documents depending on the
execution (one set in the electric cabinet and a second one in the manual).
Connecting the machine to the electric mains.
Attention!
Only specialists qualified in electrical operation of machines,
instructed in high voltage safety operation may have access to the
electric cabinet.
Attention!
When input main switch QSо is switched off and after having carried
out an additional check for availability of voltage, the following
instruction should be fulfilled
- to check whether the electrical data of the machine meet the data of
the supply mains;
- the supply cable cross-section should not be less than 4 x 4мм2,
and the cable to be well insulated and shielded (set in a pipe) in the
portion near the machine;
- the reliable PE connection of the machine should be executed in full
compliance with the electrical safety regulations in effect in the
respective country;
- to check the contact surfaces of the electrical apparata;
- if the electric motors have become considerably wet as a result of
longer transport in high humidity climate, or longer stay in a wet
room or others, to check their electric isolation resistance and
restore it, if necessary.
After having done the above, connect the three wires of the supply cable to
terminals 1, 2, and 3 and the protection wire – to terminal PE.
The point with mark to be securely earthed.

17.2. PROTECTION
Attention!
The electric installation is protected against short circuit and
overload in the following way:
- The main motor M1 is protected by motor protection QM1; coolant
pump motor by protection QM2; rapid traverse motor М3 by motor
protection QM3.
- transformer ТС is protected against short circuit by automatic
switches FU1… FU4.
17.3. COMMISSIONING OF THE MACHINE INTO OPERATION

( MAIN ELECTRICAL DIAGRAM)
In order to commission the machine into operation the main switch QS0 is
switched on first. When doing this the interlocking disconnecting switches SQ5
(closed cover of the quadrant), SQ3 (safety guard of the universal) and the SQ4
(clutch blocking) should be closed. When QS0 is switched on the HL lamp on the
electric panel goes on, which shows that the machine is ready for operation.
Main electric motor M1 is started by pressing button S1, whereby the contactors
for control of M1 are switched on and lamp HL1 on the respective button goes on.
The main electric motor is stopped by pressing button SВ0.1.
The electric motor of cooling pump M2 is started and stopped by switch SB2.
The rapid traverse electric motor M3 is started by pressing button SB3, which
is located on the carriage. When it is released, motor M3 stops.
The lighting lamp is switched on and off by switch SB4, which is located on the
control panel.
Attention!
The electric cabinet is provided with electronic block МВ50 for the
spindle emergency stop.
The electronic block MB50 (A1) is activated by pressing any emergency stop
pushbuttons SB0 (located on the control panel) or SB5 (located on the carriage)
whereat contactor M1 is switched Off and contactor KM1.1 is switched On. Contactor
KM1.1 feed a permanent voltage from block MB50 thyristor rectifier to M1 windings
and the spindle stops just for a time as adjusted by the potentiometer “t” on the
brake front panel. The block MB50 switch Off contactor KM1.1 when adjusted time
elapsed.
Attention!
The machine can be put in operation again after the removal of the
emergency and restoring of button SB0 and SB5 .
17.4. SERVICING AND MAINTENANCE
Attention!
The electrical installation should be inspected and repaired only after
the machine has been disconnected from the supply mains by means
of main switch QS0 and then be checked for absence of voltage in the
machine.
Attention!
To ensure a safe operation of the machine, it is necessary to
regularly inspect the PE connection for compliance with the electrical
safety regulations in effect in the respective country.
When the machine is in operation the voltage may not exceed its rated value
by more than 10%.
Dust and other contaminants on electric motors should be regularly cleaned.
Under normal operating conditions the lubrication of the bearings should be replaced
every 2 000 working hours, by filling the bearing space with grease up to 2/3 of its
volume.
Attention!
The EL local lighting lamp should not be more than 20W. Defective
electrical devices and elements may be replaced only by such of the
same type and electrical specification.
When connected to the supply mains for the first time, as well as
after repair, the machine should be tested under no load.
No List of documents contained in shipping Designation

documentation
1 Installation diagram Е 100
2 Main electric diagram Е 210
3 List of components Е 241
4 Location of components in the panel Е 250

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C400TM operation and maintenance manual _eng -1-

THEREFORE IT IS IMPERATIVE TO MAKE YOURSELF FAMILIAR WITH

The machine design is being improved continuously by our company experts,

TELEPHONE: (+359 44) 662 890

The safety standards, described in principle below should be complied with

Normal execution Special execution

Certificate for completeness

MODEL: Universal lathe ................................................

The lathe is completed in accordance with the contract for scope of

Date:.............20...... Head of Commercial

MODEL: Universal lathe.......…............................................

Has been packed at the ZMM – Sliven AD company in accordance

MODEL: Universal lathe...........…............................................

Has been conserved at ZMM – Sliven AD in accordance with the

MODEL: Universal lathe………….............................................

Name and family name

Item Name Pcs Note

2.2 SPECIAL EXECUTION

2.3 ADDITIONAL ACCESSORIES

Item Name Pcs Note

2.4 INDISPENSABLE SPARE PARTS

3.1. WORKING ZONE

3.2. CONNECTING DIMENSIONS OF SPINDLE

4.1. SAFETY MEASURES

4.2. SAFETY PRECAUTIONS DURING OPERATION

The machine is designed in accordance with the basic requirements of the

4.3. REQUIREMENTS FOR THE MACHINE.

The following is not allowed:

To operate the machine under inadequate working place organization, working

4.4. SAFETY DEVICES BUILT IN THE MACHINE

4.5. REQUIREMENTS WHEN REPAIRING THE MACHINE

The machine is transported in a special crate or set only on a wooden slide. It is

The machines can be stored in two ways:

5.4. LIFTING AND HANDLING.

When unloading the lathe from the transport vehicle, it is recommendable to

Do not stay under lifted load!

5.5. REMOVAL OF CONSERVATION STUFF

5.6. POSITIONING, FOUNDATION AND LEVELING

To achieve faultless operation of the machine and maintain its accuracy, it is

РМС 750 1000 1500

Note: All dimensions in mm

5.7. CONNECTION TO THE ELECTRIC MAINS

The machine should be connected to the electric mains by a qualified,

Machine operation is checked on the basis of the main electric diagram.

5.8. COMMISSIONING INTO OPERATION.

Before initial commissioning into operation or after a prolonged period of

Fill tank with coolant.

5.9. EMERGENCY STOP.

It may occur when:

6.2. KINEMATIC DIAGRAM (Fig.6.2)

6.3. GENERAL INFORMATION ABOUT MAIN UNITS

6.3.2. GEAR BOX

6.3.4. FEED BOX

6.3.6. LOWER CARRIAGE

6.3.7. UPPER CARRIAGE

1. Live center is knocked out by means of the quill travel screw.

7.1. CLAMPING AND DRIVING DEVICES

The lathe is completed with a follower and a steady rest.

7.3. TAPER ATTACHMENT.

The taper turning attachment is an additional accessory of the lathe used to

7.4. THREAD INDICATOR

8.1. GENERAL INSTRUCTIONS

The correct operation and servicing of the machine is a guarantee to preserve